Realtime payload mapping for loader/hauler system optimization

ABSTRACT

A payload optimization system is disclosed and may include one or more visual sensors operably coupled to a hauling machine and configured to scan and produce a payload body data set. The system may further include a loading machine including a payload bucket configured to load a payload into the payload body. Moreover, a loading system controller may be communicably coupled to each of the hauling machine and the loading machine and configured to identify the hauling machine and the loading machine using a set of machine identifiers. Moreover, the controller may receive the payload body data set from the one or more visual sensors, generate a payload body map, and program a loading sequence of the payload body based on the payload body map. The loading system controller may transmit and display the loading sequence configured to guide a loading cycle between the hauling machine and the loading machine.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to hauling and loading machinesand, more particularly, relates to a system for optimizing the loadingof a hauling machine.

BACKGROUND OF THE DISCLOSURE

Work machines, such as hauling trucks, loaders, shovels, excavators,articulated trucks, off-road machines, on-road machines, dozers, and thelike may be used in mining, construction, agriculture, petroleum, andother such applications. During operation, one or more work machines maywork together to perform a desired task. In one non-limiting example, ahauling machine and a loading machine may be paired together at ajobsite. The loading machine may be tasked with scooping up material ina loading bucket and filling a hauling body of the hauling machine. Insome cases the loading machine may be configured to scoop and load avariety of work material into the hauling machine such as large rocks orboulder, small rocks, gravel, dirt, and the like.

Typically, an operator of the loading machine may be tasked withdeciding which work material to scoop up with the loading bucket anddump into the hauling machine. Furthermore, it may be left to theoperator of the loading machine to make the decision where tospecifically dump the work material within the hauling body of thehauling machine. However, each load of work material may exhibit avariation in total weight and volume due to the loads having a differentcomposition of large rocks, small rocks, dirt, gravel, and the like. Asa result, it may be difficult for the operator to properly balance eachload when placing it into the hauling machine. For example, the operatormay not be able to properly view the previously placed loads. Thereforethe operator may be unable to pick out the best place to dump subsequentloads of work material into the hauling body. Additionally, someoperators may not have sufficient knowledge or training in the properloading techniques for the variety of work machines present at thejobsite. As a result, it may be desired to configure a system to analyzeand monitor the hauling and loading machine such that the system may beable to determine an optimized position for placing the work materialinto the hauling machine.

A system and method for automating a task of a construction machine isdisclosed in U.S. Patent Application Publication No. 2015/0376869entitled, “Method and Apparatus for Machine Synchronization,” (the '869publication). The synchronization system disclosed therein is installedon construction machines and configured to facilitate the exchange ofinformation between two or more machines over a communications network.The synchronization system of the '869 publication further includessensors located on the machines which provide on-board measurements suchas swing data, tilt and positioning. Additionally, the machines may beconfigured to automate the task of loading a dump truck. On boardmeasurements of the excavator and dump truck are processes and appliedagainst a model of operational practices to generate the automatedcontrol messages. The release location where the excavator dumps theload is determined based on the load-imbalance data from sensors on thedump truck. One or more load sensors may be placed throughout the bed ofthe dump truck or may be placed on a bucket of the excavator.

However, the '869 publication does not visually scan the dump truck bedto produce an image map of the dump truck bed which is analyzed todetermine an optimized location for the excavator to place the load onthe dump truck.

SUMMARY OF THE DISCLOSURE

In accordance with one embodiment, a payload optimization system forloading a set of work machines is disclosed. The payload optimizationsystem may include one or more visual sensors operably coupled to ahauling machine, the one or more visual sensors configured to scan apayload body of the hauling machine and produce a payload body visualdata set. The payload optimization system may further comprise a loadingmachine including a payload bucket configured to load a payload into thepayload body of the hauling machine. Moreover, a loading systemcontroller may be communicably coupled to each of the hauling machineand the loading machine. The loading system controller may be configuredto identify the hauling machine and the loading machine using a set ofmachine identifiers received from the hauling machine and the loadingmachine. Additionally, the loading system controller may receive thepayload body visual data set from the one or more visual sensors andgenerate a payload body map based on the payload body visual data set.Furthermore, the loading system controller may program a loadingsequence of the payload body based on the payload body map and transmitthe loading sequence to the loading machine. The loading systemcontroller may display the loading sequence on a loading machine displaydevice and the loading sequence may be configured to guide a loadingcycle between the hauling machine and the loading machine.

In accordance with another embodiment, a method of optimizing a payloadposition within a work machine is disclosed. The method may includeidentifying a hauling machine and a loading machine using one or morevisual sensors coupled to a frame of the hauling machine. The method mayfurther include receiving a payload capacity of the hauling machine froma machine specification data base on an identification of the haulingmachine. Scanning a payload body of the hauling machine with the one ormore visual sensors to produce a payload body visual data set. Themethod may further include generating a payload body map based on thepayload body data set and programming a loading sequence of the payloadbody based on the payload body map and the loading capacity of theloading machine. Moreover, the method may include transmitting theloading sequence to the loading machine to guide a loading cycle of thehauling machine.

In accordance with yet another embodiment, a controller for optimizingthe operation of a work machine is disclosed. The controller may includea machine specification module including a payload capacity for ahauling machine and a loading capacity for a loading machine. Thecontroller may further include a vision data module configured toreceive a visual data set collected from one or more visual sensorsoperably coupled to the hauling machine and the one or more visualsensors may be configured to scan a payload body of the hauling machineand produce a payload body data set. Moreover, a payload mapping modulemay be configured to receive the payload body data set and generate apayload body map. The controller may further include a loading sequencemodule which is configured to program a loading sequence of the payloadbody of the hauling machine based on the payload body map and theloading capacity. Additionally, the controller may include acommunication module configured to transmit the loading sequence to theloading machine to guide a loading cycle of the hauling machine.

These and other aspects and features of the present disclosure will bemore readily understood upon reading the following detailed descriptionin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a set of work machines at a jobsite, inaccordance with an embodiment of the present disclosure;

FIG. 2 is a schematic view of an exemplary jobsite including the set ofwork machines of FIG. 1, in accordance with an embodiment of the presentdisclosure;

FIG. 2a is a schematic side view of one machine of the set of workmachines of FIG. 1, in accordance with an embodiment of the presentdisclosure;

FIG. 2b is a schematic top view of the set of work machines of FIG. 1operating around the jobsite of FIG. 2, in accordance with an embodimentof the present disclosure;

FIG. 3 is a schematic view of an exemplary jobsite including the set ofwork machines of FIG. 1, in accordance with an embodiment of the presentdisclosure;

FIG. 3a is a schematic side view of one machine of the set of workmachines of FIG. 1, in accordance with an embodiment of the presentdisclosure;

FIG. 3b is a schematic top view of the set of work machines of FIG. 1operating around the jobsite of FIG. 3, in accordance with an embodimentof the present disclosure;

FIG. 4 is schematic diagram of a control system for optimizing theloading of the set of work machines of FIG. 1, in accordance with anembodiment of the disclosure; and

FIG. 5 is a flow chart of a method executed by the control system ofFIG. 3 for optimizing the loading of the set of work machines of FIG. 1,in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings and with specific reference to FIG. 1, ajobsite 20 with a set of work machines 22 is shown, in accordance withcertain embodiments of the present disclosure. While one non-limitingexample of the set of work machines 22 may include a hauling machine 24and a loading machine 26, it will be understood that the set of workmachines 22 may include other types of machines such as but not limitedto, an on-road truck, an off-road truck, a motor grader, industrialmining equipment, a locomotive, and any other such machines. The haulingmachine 24 may include a frame 28 configured to support a power source30, and an operator compartment or operator cabin 32. In someembodiments, the power source 30 may be a power generating source suchas but not limited to, a diesel combustion engine, a gasoline combustionengine, a generator, an electric motor, any other known power generatingsource or a combination thereof. Moreover, the operator compartment 32may include a hauling machine control unit 34 and a set of operationalcontrols such as but not limited to, a steering input device (notshown), throttle controls (not shown), machine implement controls (notshown), and other such operational controls. Alternatively, the haulingmachine 24 may be configured as a fully autonomous vehicle andconfigured without the operator compartment 32. Moreover, in the fullyautonomous configuration the hauling machine control unit 34, or othersuch controller, may be configured to control and operate the haulingmachine 24 operational controls (i.e., electro-hydraulic controls,electric controls, or hydraulic controls). Additionally, the haulingmachine 24 may include a payload body 36 or other such hauling containersupported by the frame 28. In some embodiments, the payload body 36 maybe configured to be filled with a work material 37 or payload such asdirt, stone, gravel, and the like. Moreover, the payload body 36 may bepivotally attached to the frame 28 and coupled to one or more dumpactuators 38 such that the payload body 36 may be raised and/or loweredin order to empty the work material 37 from the payload body 36. Thehauling machine 24 may further include a set of ground engaging elements40 rotatably coupled to the frame 28 and driven by the power source 30to propel the hauling machine 24 around the jobsite 20. Although the setof ground engaging elements 40 are shown as wheels, other types ofengagement devices, such as continuous tracks and the like, may be used.

Similarly, the loading machine 26 may include a frame 42 configured tosupport a power source 44, and an operator compartment or operator cabin46. In some embodiments, the power source 44 may be a power generatingsource such as but not limited to, a diesel combustion engine, agasoline combustion engine, a generator, an electric motor, any otherknown power generating source or a combination thereof. Moreover, theoperator compartment 46 may include a loading machine control unit 48and a set of operational controls such as but not limited to, a steeringinput device (not shown), throttle controls (not shown), machineimplement controls (not shown), and other such operational controls.Alternatively, the loading machine 26 may be configured as a fullyautonomous vehicle and configured without the operator compartment 32.Moreover, in the fully autonomous configuration the loading machinecontrol unit 48, or other such controller, may be configured to controland operate the loading machine 26 operational controls (i.e.,electro-hydraulic controls, electric controls, or hydraulic controls).Additionally, the loading machine 26 may include a payload bucket 50 orother such loading apparatus. In some embodiments, the payload bucket 50may be used to scoop or otherwise pick up the work material 37 orpayload such as boulders, dirt, stone, gravel, and the like. Moreover,the payload bucket 50 may be coupled to one or more attachment arms 52and movably attached to the frame 42. Furthermore, the one or moreattachment arms 52 may include an actuator 54 configured to raise and/orlower the attachment arms 52 and the payload bucket 50. In onenon-limiting example, an operator of the loading machine 26 may fill thepayload bucket 50 with the work material 37 and load or otherwise dumpit into the payload body 36 of the hauling machine 24. Moreover, theloading machine 26 may further include a set of ground engaging elements56 rotatably coupled to the frame 42 and driven by the power source 44to propel the loading machine 26 around the jobsite 20. Although the setof ground engaging elements 56 are shown as wheels, other types ofengagement devices, such as continuous tracks and the like, may be used.It is to be understood that the set of work machines 22 is shownprimarily for illustrative purposes to assist in disclosing features ofvarious embodiments of the present disclosure, and that FIG. 1 may notdepict all of the components of the set of work machines 22.Furthermore, a single set (i.e., one hauling machine 24 and one loadingmachine 26) of work machines 22 is shown for simplicity, and more thanone set of work machines 22 may be in operation at the jobsite 20

Referring now to FIG. 2, with continued reference to FIG. 1, anexemplary jobsite 20 including the hauling machine 24 and loadingmachine 26 is shown. While a single hauling machine 24 and a singleloading machine 26 is shown, it will be understood that multiplehauling, loading and other such machines and equipment may be operatingaround the jobsite 20. Furthermore, FIG. 2a illustrates a side view ofthe hauling machine 24 with an empty payload body 36, while FIG. 2billustrates a top view of the hauling machine 24 and loading machine 26operating around the jobsite 20. As further illustrated in FIG. 2b ,during operation the loading machine 26 may be configured to scoop, orotherwise fill, the payload bucket 50 with the work material 37 (i.e.,payload) and then position the load of work material 37 into the payloadbody 36 of the hauling machine 24. The loading machine 26 may deliverand position multiple loads of the work material 37 into the payloadbody 36. Once the payload body 36 is filled, the hauling machine 24 maytransport the work material 37 to another location on the jobsite 20.Alternatively, the hauling machine 24 may transport the work material 37to a location outside of the jobsite 20.

In one non-limiting example, the hauling machine 24 may include one ormore visual sensors 58 such as but not limited to, a video camera, aRADAR scanning device, a LIDAR scanning device, 3D scanning device, orother such visual device. The one or more visual sensors 58 may beoperably coupled to the payload body 36 or other such portion of thehauling machine 24 and configured to scan and monitor the payload body36. In some embodiments, the one or more visual sensors 58 may bepositioned to scan and monitor the payload body to produce a payloadbody visual data set. The payload body visual data set may providevisual images or other data of the interior of the payload body 36. Forexample, as illustrated in FIGS. 2a and 2b , the one or more visualsensors 58 may be mounted or otherwise arranged at an elevated positionof the payload body and configured to scan and monitor a payload volume60 of the payload body 36. Moreover, in some embodiments, the one ormore visual sensors 58 may be adjustable such that an operator of thehauling machine 24 may control and adjust the one or more visual sensors58 to scan and monitor different portions of the payload body 36.Additionally or alternatively, the one or more visual sensors 58 may becontrollably configured to scan the entire payload volume 60 of thepayload body 36.

Prior to the start of a loading operation between the loading machine 26and hauling machine 24, the one or more visual sensors 58 may beconfigured to scan and collect the payload body visual data set of theentire payload volume 60. The payload body visual data set may beanalyzed by the hauling machine control unit 34 to confirm the payloadbody 36 is empty and ready to accept the work material 37 from theloading machine 26. If residual work material 37 is observed, the one ormore visual sensors 58 may be configured to signal the operator of thehauling machine 24, the loading machine 26 or other interested personnelthat the hauling machine 24 may not be ready to accept a load of workmaterial 37. Alternatively, in the case where a set of fully autonomouswork machines 22 are used at the jobsite 20, the one or more visualsensors 58 may be configured to signal an automated control system ofthe hauling machine 24 and/or loading machine 26 that the haulingmachine 24 may not be ready to accept a load of work material 37. WhileFIGS. 2a and 2b show the one or more visual sensors 58 attached to thepayload body 36 above the operator compartment 32, it will be understoodthat the one or more visual sensors 58 may be positioned in additionaland/or alternative locations. In some embodiments the one or more visualsensors 58 may be mounted on both the hauling machine 24 and loadingmachine 26. Alternatively, the one or more visual sensors 58 may just bemounted on the loading machine 26 and configured to scan and monitor thework material 37 scooped up and contained within the payload bucket 50.

In addition to the one or more visual sensors 58, the hauling machine 24and/or the loading machine 26 may have additional monitoring systemswhich have additional sensors, such as pressure sensors, positionssensors, strain sensors, orientation sensors, and other such sensors. Insome embodiments, the hauling machine 24 and loading machine 26 maycombine the data collected by the one or more visual sensors 58 withdata collected by the additional sensors installed on the machine toconfirm the payload body 36 is empty. For example, the hauling machine24 may be equipped with sensors 62 such as but not limited to, pressuresensors, position sensors, strain sensors, vibration sensors,orientation sensors or other such sensors coupled to the suspensionsystem 64 of the hauling machine 24. In some embodiments, the sensors 62may be configured to provide a condition signal of the payload body 36such as, full, partially full, empty, or other such condition. Moreover,the loading machine 26 may be configured with sensors 66, such as butnot limited to, pressure sensors, position sensors, strain sensors,weight sensors, orientation sensors, vibration sensors, or other suchsensors located on the payload bucket 50, the attachment arms 52 orother such location of the loading machine 26. The sensors 66 on theloading machine 26 may be configured to determine a weight and/ordensity of the work material 37 that is contained in the payload bucket50.

The hauling machine 24 and the loading machine 26 may each respectivelybe configured with a hauling machine control unit 34 and loading machinecontrol unit 48. Generally, the hauling machine control unit 34 and theloading machine control unit 48 may be configured to control and executeoperational procedures of the machines. Moreover, the hauling machinecontrol unit 34 may be configured with a hauling machine communicationmodule 68 and loading machine control unit 48 may be configured with aloading machine communication module 70 such that a communication link72 may be established between the hauling machine 24 and the loadingmachine 26. As a result, the hauling machine control unit 34 and theloading machine control unit 48 may communicate with each other, as wellas, transmit data and other information to one another. Furthermore, thecommunication link 72 may utilize a wireless communication network 74set up around the jobsite 20 which may enable direct communication anddata transfer between the hauling machine communication module 68 andthe loading machine communication module 70. The wireless communicationnetwork 74 may be configured as a data communication network such as, aBluetooth network, a near-field communication network, a radio frequencycommunication network, a computer data network, a Wi-Fi data network, acellular data network, a satellite data network, or other such datacommunication network. As a result, the hauling machine 24 and theloading machine 26 may be capable of transmitting or otherwise sharingvoice data, visual data, machine data, and other such data between oneanother. For example, the payload body visual data set collected by theone or more visual sensors 58 may be transmitted from the haulingmachine control unit 34 to the loading machine control unit 48 and theloading machine control unit 48 may utilize the payload body visual dataset during the operation of the loading machine 26.

Additionally, a back office operations center 76 may be locatedsomewhere around the jobsite 20, and the back office operations center76 may include a loading system controller 78 that is programmed orotherwise configured to monitor, command and control the movement andactivity of the hauling machine 24, the loading machine 26 and othersuch equipment located around the jobsite 20. In some embodiments, theloading system controller 78 may be communicably coupled with thehauling machine communication module 68 and the loading machinecommunication module 70 through the wireless communications network 74described above (i.e., Bluetooth network, near-field communicationnetwork, radio frequency communication network, computer data network,Wi-Fi data network, cellular data network, satellite data network, orother such data communication network). As a result, the loading systemcontroller 78, the hauling machine control unit 34, and the loadingmachine control unit 48 may all be communicably coupled and configuredto transmit and receive data between one another.

The loading system controller 78 may be configured to analyze theworkload around the jobsite 20 and implement an operation plan which mayminimize the loading cycle between the hauling machine 24 and theloading machine 26. Such optimization not only may improve efficiencyaround the jobsite 20 but may produce other benefits as well such as butnot limited to, reducing fuel consumption, increasing operationallifespan of the hauling machine 24 and loading machine 26, increasingtime between maintenance intervals, improving safety, and other suchoperational improvements and benefits. In one non-limiting example, theloading system controller 78 may be configured to identify the specifichauling machine 24 and the loading machine 26 being used at the jobsite20. The loading system controller 78 may identify each machine throughcommunication with the hauling machine control unit 34 and loadingmachine control unit 48. Moreover, the loading system controller 78 mayhave a database which includes a variety of hauling machine 24 andloading machine 26 parameters such as but not limited to, payloadcapacity, hauling capacity, and other such machine parameters.

Additionally, the loading system controller 78 may receive the payloadbody visual payload body visual data set collected by the one or morevisual sensors 58 configured to scan the payload volume 60 of thehauling machine 24. Once received, the loading system controller 78 maybe programmed to analyze the payload body visual data set and generate apayload body map of the payload body 36. The payload body map may showtopographical features such as but not limited to, the surfacetopography and payload area of the payload body 36. Moreover, thepayload body map may be analyzed to determine the available payloadvolume 60 of the payload body 36. In one non-limiting example, prior tothe start of the loading sequence, the loading system controller 78 mayanalyze the payload body map generated from the payload body visual dataset to confirm the payload body 36 is empty, such as illustrated inFIGS. 2a and 2b . Furthermore, the loading system controller 78 may beconfigured to transmit a signal if an undesirable condition is detected,such as the payload body 36 is not empty or contains material from aprevious loading cycle (i.e., carryback) or other such condition.Furthermore, in some embodiments, the loading system controller 78 mayreference the payload body map to program or otherwise generate aloading sequence for the loading machine 26 to follow during loading thepayload body 36 of the hauling machine 24. The loading sequence may betransmitted or otherwise sent from the loading system controller 78 tothe hauling machine control unit 34 and the loading machine control unit48.

Moreover, in a manually operated system (i.e., operator occupied haulingmachine 24 and loading machine 26), the loading sequence may bedisplayed on an operator display unit (not shown) located within theoperator compartments 32, 46 of the hauling machine 24 and loadingmachine 26 to guide the operator to deliver the work material 37 to afirst target dump zone 80 within the payload body 36 during the loadingsequence. Alternatively, in an automated system (i.e., autonomoushauling machine 24 and loading machine 26), the loading sequence may bereceived by the hauling machine control unit 34 and loading machinecontrol unit 48 and used to instruct and guide the loading machine 26 toautonomously deliver the work material 37 to the first target dump zone80 within the payload body 36 of the hauling machine 24.

Referring now to FIG. 3 with continued reference to FIGS. 1-2, thehauling machine 24 and the loading machine 26 are illustrated operatingaround the jobsite 20 during the loading cycle. Furthermore, FIG. 3ashows a side view of the hauling machine 24 with a partial load of thework material 37 loaded into the payload body 36 and FIG. 3b shows a topview the hauling machine 24 with the partially filled payload body 36and loading machine 26 with a filled payload bucket 50 operating aroundthe jobsite 20. The one or more visual sensors 58 may be furtherconfigured to monitor and scan the payload body 36 and/or the payloadbucket 50 during the loading cycle. For example, after the loadingmachine 26 loads the work material 37 into the first target dump zone80, previously identified by the loading system controller 78 andcommunicated to the hauling machine 24 and the loading machine 26, theone or more visual sensors 58 may perform another scan of the payloadbody 36. As discussed above, the one or more visual sensors 58 may bemounted on the hauling machine 24, the loading machine 26 or both, andthe one or more visual sensors 58 may include a camera, a RADAR scanningdevice, a LIDAR scanning device, a 3D scanning device, or other suchdevice. Therefore, the one or more visual sensors 58 may be configuredto scan the payload body 36 and the payload volume 60 to determine thestate of the work material 37 placed in the hauling machine 24. In someembodiments, the one or more visual sensors 58 may collect an updatedpayload body visual data set which is communicated or otherwisetransmitted to the hauling machine control unit 34 and/or the loadingmachine control unit 48. Moreover, the payload body visual data set maybe further communicated from the hauling machine control unit 34 and/orthe loading machine control unit 48 to the loading system controller 78located in the back office operations center 76.

During the loading of the hauling machine 24, the loading machine 26 mayalso monitor the work material 37 which is scooped up by the payloadbucket 50. The loading machine 26 may be configured with one or moreadditional sensors 66 mounted on the payload bucket 50, the, theattachment arms 52, or other location of the loading machine, and theone or more sensors 66 may be configured to determine the weight of thework material 37 in the payload bucket 50. Furthermore, as discussedabove, one or more visual sensors 58 may be mounted on the loadingmachine 26 and configured to scan the payload bucket 50 to generate aloading bucket visual data set. In some embodiments, the loading bucketvisual data set may be transmitted by the loading machine communicationmodule 70 to the loading system controller 78. As a result, the loadingsystem controller 78 may analyze the payload bucket visual data set andthe data collected by the additional sensors 66 to determine the weight,volume, composition, or other such characteristic of the work material37 scooped up by the loading machine 26 and contained within the payloadbucket 50.

Following the placement of the first load of work material 37 in thefirst target dump zone 80 of the payload body 36, the loading systemcontroller 78 may receive and analyze the updated payload body visualdata set and generate an updated payload body map of the payload body36. Furthermore, the loading system controller 78 may receive thepayload bucket visual data set and data collected from the additionalsensors 66 mounted on the loading machine 26. Based on the updatedpayload body visual data, payload bucket visual data, and data from theadditional sensors 62, 66 the loading system controller 78 may analyzethe condition of the of the work material 37 that is placed in thepayload volume 60 of the payload body 36 and determine a second oradditional target dump zone 82 for the work material 37. For example,the loading system controller 78 may reference the previously generatedpayload body map to determine whether the work material 37 was loadedinto the correct location of the payload body (i.e., the first targetdump zone 80). Moreover, the loading system controller 78 may thenanalyze the additional data received from the hauling machine 24 andloading machine 26 and determine a preferred or optimized location toplace subsequent loads of work material (i.e., the second or additionaltarget dump zone 82). In some embodiments, the loading system controller78 may analyze the payload body visual data, the payload bucket visualdata, and data from the additional sensors 62, 66 to search for anyundesirable conditions of the payload body 36 and payload bucket 50 suchas but not limited to, an imbalanced load, presence of large/oversizedboulders, an overload condition, or other such conditions.

Referring now to FIG. 4, a schematic of a payload optimization system 84is shown. The payload optimization system 84 may be configured tomonitor and control work activities such as but not limited to, loading,hauling, unloading, and other associated activities of hauling andloading machines 24, 26 operating in and around the jobsite 20. In someembodiments, the payload optimization system 84 may include the loadingsystem controller 78 which is programmed to send and receive datasignals, control signals, and other information between the haulingmachine 24, the loading machine 26 and other such equipment locatedaround the jobsite 20. More specifically, the loading system controller78 may be communicably coupled with equipment at the jobsite 20 throughthe wireless communication network 74 (i.e., Bluetooth network,near-field communication network, radio frequency communication network,computer data network, Wi-Fi data network, cellular data network,satellite data network, or other such data communication network). Forexample, the loading system controller 78 may include a loading systemcommunication module 85 that communicates with the hauling machinecommunication module 68 and the loading machine communication module 70over the wireless communication network 74. As a result, the loadingsystem controller 78 may transmit operational commands to the haulingand loading machines 24, 26 which may provide a set of loadinginstructions for the optimal loading of work material 37 into thepayload body 36.

The loading system controller 78 may include a microprocessor 86 forexecuting the software, programs, and/or algorithms that are configuredto control, measure, and monitor the operation of the hauling machine 24and the loading machine 26. Moreover, the microprocessor 86 may includea memory module 88 which further includes read-only memory (ROM) 90,configured to provide storage for the software, programs, algorithms,and other executable files. The memory module 88 may also include randomaccess memory (RAM) 92, which provides storage space for the datagenerated during the execution of the software, programs, and/oralgorithms. Furthermore, the memory module 88 may include a secondarystorage module 93, such as but not limited to, a hard disk drive, asolid state drive, a flash drive, or other such data storage device.Additionally, the loading system controller 78 may be configured withsoftware or other executable data files programmed to analyze andprocess the payload body visual data set and other data and machineinformation received from the hauling machine 24, and the loadingmachine 26. Furthermore, the loading system controller 78 may output orotherwise transmit a plurality of command and control signals to directand optimize the loading of the hauling machine 24 based on the analysisand computation of the received visual data and other collectedinformation. While the microprocessor 86 is illustrated in FIG. 3, itwill be appreciated that other components such as but not limited to, amicrocontroller, an application specific integrated circuit (ASIC), orother electronic device may be used to control and operate the loadingsystem controller 78.

Furthermore, the loading system controller 78 may be operably coupled toan input/output module 94, and an operator of the payload optimizationsystem 84 may use the input/output module 94 to access and selectivelyoperate the loading system controller 78. For example, the input/outputmodule 94 may be configured to allow the operator to input or executecommands to the loading system controller 78 through a keyboard, amouse, a dial, a button, a joystick, a touch screen, a microphone, orother known input device. Additionally, data and other such informationprovided by the loading system controller 78 may be output to a displaydevice such as but not limited to, a monitor, a speaker, a video screen,or other visual/audio display device capable of providing the output ofthe loading system controller 78 to the operator. In some embodiments,the input/output module 94 may be coupled to the loading systemcontroller 78 through a wired connection and the input/output module 94may be adjacently positioned to the loading system controller 78 in theback office operations center 76. Alternatively, the input/output module94 may be coupled to the loading system controller 78 through a wirelesscommunication network such as, a Bluetooth network, a near-fieldcommunication network, a radio frequency communication network, acomputer data network, a Wi-Fi data network, a cellular data network, asatellite data network, or other such data communication network.Furthermore, the input/output module 94 may be configured as a handheldmobile device wirelessly connected to the loading system controller 78such as but not limited to, a tablet computer, a smart phone, a cellularphone, a laptop computer, or other such mobile electronic device. As aresult, the operator and the input/output module 94 may be remotelylocated from the loading system controller 78. In some embodiments, theinput/output module 94 may be configured such that operator remotelycommunicates with the loading system controller 78 to control andmonitor the payload optimization system 84 from a location other thanthe back office operations center 76. Moreover, a supervisor, planner,mechanic, autonomous control system, or other interested personnel orsystem may be able to access the loading system controller 78 from aseparate input/output module 94 which remotely communicates with theloading system controller 78 to monitor and view the activity of thework machines 22.

During operation, the payload optimization system 84 may be configuredto control, monitor and update the loading activities of the hauling andloading machine 24, 26 operating around the jobsite 20. In someembodiments, the hauling machine 24 may include the hauling machinecontrol unit 34 that is coupled to the hauling machine communicationmodule 68. In some embodiments, the hauling machine communication module68 communicably couples the hauling machine 24 to the loading machine26, the loading system controller 78 and other such communicationdevices located around the jobsite 20 that may be connected to thewireless network 74. Additionally, one or more visual sensors 58 (i.e.,camera, RADAR, LIDAR, or 3D scanning device) may be attached to thehauling machine 24 and configured to scan and collect visual data of thepayload body 36 (FIGS. 2 and 3). Furthermore, additional sensors 62 maybe mounted at various locations around the hauling machine 24 andconfigured to collect operational data of the hauling machine 24. In onenon-limiting example, additional sensors 62 may be mounted on thehauling machine suspension system 64 (FIGS. 2 and 3) and configured tomeasure and monitor the payload body 36 and other components of thehauling machine 24. In some embodiments, data collected by the one ormore visual sensors 58 and the additional sensors 62 may be usedtogether to determine the state or condition of the work material 37(FIGS. 2 and 3) loaded into the payload body 36.

The one or more visual sensors 58 may be configured to scan the payloadbody 36 and collect the payload body visual data set. The payload bodyvisual data set may be directly transmitted to a hauling machine displayunit 96 mounted in the operator compartment 32 (FIGS. 1-3) of thehauling machine 24. As a result, the operator of the hauling machine 24may be able to visually confirm the state of the work material 37 loadedin the payload body 36 (FIGS. 2 and 3). For example, the visual data setmay display information indicating the payload body is empty, partiallyfull, completely full, or other such information. Moreover, the visualdata set collected by the one or more visual sensors 58 may betransmitted to the loading system controller 78 for further analysis.Data and information collected by the additional sensors 62 included onthe hauling machine 24 may be combined with the visual data set to helpthe operator of the hauling machine 24 monitor the state or condition ofthe work material 37 in the payload body 36 (FIGS. 2 and 3). Datacollected by the additional sensors 62 may be received by the haulingmachine control unit 34 and communicated to the operator through thehauling machine display unit 96. Additionally, the hauling machinecontrol unit 34 may transmit the visual data set, and informationcollected by the additional sensors 62 to the loading system controller78 for further analysis.

The loading machine 26 may be similarly equipped with a loading machinecontrol unit 48 that is coupled to the loading machine communicationmodule 70. In some embodiments, the loading machine communication module70 may communicably couple the loading machine 26 to the hauling machine24, the loading system controller 78 and other such communicationdevices located around the jobsite 20 that may be connected to thewireless network 74. Furthermore, the loading machine may have one ormore visual sensors 58 (i.e., camera, RADAR, LIDAR, or 3D scanningdevice) attached to the loading machine 26 and configured to scan thepayload bucket 50. Furthermore, additional sensors 66 may be mounted atvarious locations around the loading machine 26 and configured tocollect operational data of the loading machine 26. In one non-limitingexample, additional sensors 66 may be mounted on the payload bucket 50(FIGS. 2 and 3) and/or the attachment arms 52 and configured to measureand monitor the work material 37 weight and volume in the payload bucket50. In some embodiments, data collected by the one or more visualsensors 58 and the additional sensors 66 may be used in combination todetermine the state or condition of the work material 37 (FIGS. 2 and 3)loaded into the payload body 36.

The one or more visual sensors 58 may be configured to scan the payloadbucket 50 and collect the payload bucket visual data set. The payloadbucket visual data set may be directly fed to a loading machine displayunit 98 mounted in the operator compartment 46 (FIGS. 1-3) of theloading machine 26. As a result, the operator of the loading machine 26may be able to visually confirm the state of the work material 37 loadedin the payload bucket 50 (FIGS. 2 and 3). For example, the payloadbucket visual data set may display information indicating the payloadbucket is empty, partially full, completely full, or other suchinformation. Additionally, the payload bucket visual data set may allowthe operator of the loading machine 26 to view the composition of thework material 37. For example, the operator may be able to determine ifthe work material 37 includes large rocks, small rocks, gravel, loosedirt, or any other such material or combination thereof. Moreover, thepayload bucket visual data set collected by the one or more visualsensors 58 may be transmitted by the loading machine communicationmodule 70 to the loading system controller 78 for further analysis. Insome embodiments, data and information collected by the additionalsensors 66 included on the loading machine 26 may be combined with thepayload bucket visual data set to help the operator of the loadingmachine 26 monitor the state or condition of the work material 37 in thepayload bucket 50 (FIGS. 2 and 3). Data collected by the additionalsensors 66 may be received by the loading machine control unit 48 andcommunicated to the operator through the loading machine display unit98. Additionally, the hauling machine control unit 34 may transmit thepayload bucket visual data set, and information collected by theadditional sensors 66 to the loading system controller 78 for furtheranalysis.

In some embodiments, the payload optimization system 84 may beconfigured such that the loading system controller 78, the haulingmachine control unit 34 and the loading machine control unit 48 are allcommunicably coupled to one another and able to transmit and receivedata from one another. The loading system controller 78 may be furtherconfigured to analyze data which is collected by the hauling machine 24and loading machine 26 and generate a loading sequence plan for thehauling and loading machine 24, 26 to follow. As discussed above, thehauling machine 24 may be equipped with one or more visual sensors 58configured to scan the payload body 36 of the hauling machine 24 andgenerate a payload body visual data set. Moreover, the loading machine26 may be similarly equipped with one or more visual sensors 58configured to scan the payload bucket 50 of the loading machine 26 andgenerate a payload bucket visual data set. Additionally, the hauling andloading machines 24, 26 may include additional sensors 62, 66 that areconfigured to monitor and collect data from other hauling and loadingmachine 24, 26 components and systems. The payload body visual data set,the payload bucket visual data set and other data and informationcollected by the hauling and loading machine 24, 26 may be transmittedto the loading system controller 78 for analysis and generation of aloading sequence to optimize loading of the hauling machine 24 by theloading machine 26.

The loading system controller 78 may save or otherwise store data andinformation received from the loading and hauling machines 24, 26 in thememory module 88 or other such storage location such as a cloud datastorage location. In one non-limiting example, the loading systemcontroller 78 may identify the hauling machine 24 and the loadingmachine 26 based on the data and information received from each machine.The loading system controller 78 may then be able to access a machinespecification module 100, either stored locally on the loading systemcontroller 78 or on another networked computing device. The machinespecification module 100 may provide the loading system controller 78with hauling and loading machine 24, 26 information such as but notlimited to, capacity of the payload body 36, capacity of the payloadbucket 50 and other such information. Additionally, the loading systemcontroller 78 may include a payload mapping module 102 which maygenerate a payload map of the payload body 36 and/or payload bucket 50based on the payload body visual data set, the payload bucket visualdata set and other data received from the hauling and loading machines24, 26. Furthermore, the loading system controller 78 may include avision data module 103 which is configured to receive the payload bodyvision data set and the payload bucket vision data set and produce anoptimized payload vision data set which may be used by the loadingsystem controller 78 to optimize the loading operation of the haulingmachine 24.

Prior to the start of a loading sequence, the payload map of the payloadbody 36 may be analyzed to confirm the payload body 36 is empty. In someembodiments, the loading system controller 78 may generate an operatoralert or other such message if the analysis of the payload mapdetermines the payload body 36 is not empty. Additionally, the payloadvolume 60 of the payload body 36 may be determined from the payload mapanalysis. As a result, the loading system controller 78 may be able tocalculate or otherwise determine how much work material 37 can be loadedinto the payload body 36 of the hauling machine 24. The loading systemcontroller 78 may also analyze data received from the additional sensors62 coupled to the hauling machine suspension system 64 or other machinesystems to determine the state and hauling capabilities of the payloadbody 36.

In some embodiments, the loading system controller 78 may furtherinclude a loading sequence module 104 which uses the payload mapanalysis and other information received from the hauling machine 24 andthe loading machine 26 to generate a set of loading sequenceinstructions. Additionally, the loading system controller 78 mayreference hauling and loading machine 24, 26 specifications from themachine specification module and incorporate this information into theloading sequence instructions. Once the loading sequence is determined,the loading system controller 78 may transmit the set of operationalinstructions to the loading machine 26, the hauling machine 24 and anyother machine involved in the loading operation. Furthermore, once theloading sequence begins, the hauling and loading machines 24, 26 maycontinue to scan the payload body 36 and payload bucket 50 and transmitan updated payload body visual data, an updated payload bucket visualdata, and any other data collected by the additional sensors 62, 66 andmachine systems. As a result, the loading system controller 78 mayanalyze the updated data and generate an updated payload body map toconfirm that the loading sequence is properly progressing. In someembodiments, the loading system controller 78 may issue a correctedloading sequence if abnormal payload conditions such as but not limitedto, unequal load distribution, improper work material 37 placement orother such abnormal condition. Alternatively, if the corrected loadingsequence is unable to correct the deviation from the loading sequencethen the loading system controller 78 may signal the hauling and loadingmachines 24, 26 to pause the loading sequence so the problems may becorrected.

The loading system controller may also be configured with a machineparameter monitoring module 105 that is configured to receive data andinformation collected from other monitoring systems of the haulingmachine 24 and the loading machine 26. For example, the machineparameter monitoring module 105 may include a pressure sensing moduleconfigured to receive data collected by the sensors 62 mounted on thehauling machine suspension system 64. Additionally, the machineparameter monitoring module 105 may also include a payload monitoringmodule configured to receive data collected by the sensors 66 mounted onthe loading machine 26 configured to measure the load weight and/ordensity of the work material 37 contained in the payload bucket 50.

Moreover, the payload optimization system 84 may be configured tooperate in two or more operational modes. In a first mode, the haulingand loading machines 24, 26 may be configured to operate in a manual orsemi-automatic mode which may require an operator to control andmaneuver the hauling and loading machines 24, 26. In the semi-automaticmode, the loading system controller 78 may generate the set of loadingsequence instructions and transmit the instructions to the hauling andloading machines 24, 26. In some embodiments, the received loadinginstructions may be received by the hauling machine control unit 34 andthe loading machine control unit 48 and displayed to the operators ofthe hauling and loading machine 24, 26. Moreover, the loading machinedisplay unit 98 may show or otherwise instruct the operator where aspecific load of work material 37 should be placed in the payload body36 (i.e., first target dump zone 80, second or additional target dumpzone 82). Additionally, in the semi-automatic mode the loading systemcontroller 78 may continuously update the loading sequence instructionssuch that anytime the loading system controller 78 determines acorrection to the loading sequence is needed, updated instructions willbe sent to the hauling and loading machine 24, 26.

Alternatively, in a second mode, the payload optimization system 84 maybe configured to operate in a fully autonomous mode which may notrequire the physical presence of the operator in the operatorcompartments 32, 46 of the hauling and loading machines 24, 26. In thefully autonomous mode the hauling and loading machines 24, 26 may beequipped with additional sensors 62, 66 and other machine intelligencethat is configured to autonomously control and operate the hauling andloading machines 24, 26 around the jobsite 20. In one non-limitingexample, the hauling machine control unit 34 and the loading machinecontrol unit 48 may be selectably configured to activate and/ordeactivate the operation of the semi-automatic and fully autonomousmode. However, other configurations of the hauling and loading machine24, 26 are possible. Moreover, in the fully autonomous mode, the loadingsystem controller 78 may still generate the set of loading sequenceinstructions and transmit the instructions to the hauling and loadingmachine 24, 26. Once received, the hauling machine control unit 34 andloading machine control unit 48 may transmit the loading instructions tothe autonomous guidance system in the hauling and loading machine 24, 26and the guidance system will guide the loading machine 26 to place thework material 37 in the desired payload body 36 location (i.e., firsttarget dump zone 80, second or additional target dump zone 82).Additionally, in the fully autonomous mode the loading system controller78 may continuously update the loading sequence instructions such thatanytime the loading system controller 78 determines a correction to theloading sequence is needed, updated instructions will be sent to thehauling and loading machine 24, 26 and executed by the autonomousguidance system.

Additionally, the secondary storage module 93 in the memory module 88may be configured to save data received from the one or more visualsensors 58, the additional sensors 62, 66 on the hauling and loadingmachines 24, 26, the hauling machine control unit 34, the loadingmachine control unit 48, and other machine systems and components tocreate a historical operational data set of the hauling and loadingmachines 24, 26. Moreover, the loading system controller 78 may save andlog any corrective action control signals or updates to the loadingsequence instructions transmitted to the hauling and loading machines24, 26. In some embodiments, the loading system controller 78 and othercomponents of the payload optimization system 84 may be furtherconfigured to analyze the historical data set saved on the loadingsystem controller 78 to identify any operational trends or other signalswhich may allow the payload optimization system 84 to predict whenabnormal loading and/or hauling conditions may occur. Furthermore, thepayload optimization system 84 may be able to adaptively adjust orfurther optimize the loading sequence instructions based on the analysisof the historical data set.

INDUSTRIAL APPLICABILITY

In general, the present disclosure may find application in manyindustries, including but not limited to, mining, construction,agriculture, and other such industries. In some embodiments, the haulingand loading machines 24, 26 may be configured to work together around ajobsite 20. Additionally, one or more visual sensors 58 may be mountedon the hauling and loading machines 24, 24 and the one or more visualsensors 58 may be configured to scan and monitor the payload body 36 ofthe hauling machine 24 and payload bucket 50 of the loading machine 26.Furthermore, during a loading operation performed by the hauling andloading machines 24, 26, the payload optimization system 84 may beconfigured to monitor, control, and optimize the loading of workmaterial 37 into the payload body 36 of the hauling machine 24. Morespecifically, the payload optimization system 84 may generate a set ofloading instructions for the loading machine 24 to follow while loadingthe work material into the payload body 36 of the hauling machine 24.Furthermore, the payload optimization system 84 may be electronicallyand communicably coupled with the hauling and loading machines 24, 26such that the loading system controller 78 of the payload optimizationsystem may monitor and update the set of loading sequence instructionsin real time to ensure the work material 37 is optimally loaded into thehauling machine 24 and transported to its desired location.

Referring to FIG. 5, with continued reference to FIGS. 1-4, a method 106for optimally loading the hauling machine 24 is shown. In a first block108 of the method 106, the payload optimization system 84 may identifythe hauling and loading machine 24, 26 present at the jobsite 20 andready to start a new loading sequence. In one non-limiting example, thepayload optimization system 84 may use an identification signal or othersuch identifier sent from the hauling and loading machine 24, 26 andreceived by the loading system controller 78 to identify each machine.Once the hauling and loading machine 24, 26 are identified, then in anext block 110 the payload capacity of the hauling machine 24 and theloading capacity of the loading machine 26 may be determined. In someembodiments, the loading system controller 78 may use the machineidentification to reference the machine specification module 100. Themachine specification module 100 may contain information for the haulingand loading machines 24, 26, such as but not limited to haulingcapacity, loading capacity and other such machine specifications.Additionally or alternatively, an operator or other individual may inputor otherwise provide the hauling capacity and loading capacity of thehauling and loading machines 24, 26.

Once the hauling and loading capacity is determined, then in a nextblock 112 the payload body 36 of the hauling machine may be visuallyscanned by one or more visual sensors 58 mounted on the hauling machine24. The one or more visual sensors 58 may be a camera, a RADAR scanningdevice, a LIDAR scanning device, a 3D scanning device, or other suchscanning device which is configured to scan the payload body 36.Moreover, the one or more visual sensors 58 may produce a payload bodyvisual data set which is transmitted to the loading system controller 78located in the back office operations center 76 or other such location.The loading system controller 78 may analyze the payload body visualdata set to determine the condition of the payload body 36 (i.e., empty,partially full, or full). Typically, the optimized loading of thehauling machine 24 will not begin until the payload body 36 is confirmedto be empty and otherwise ready to receive a load of work material 37.Additionally, the hauling machine may be configured with additionalsensors 62 coupled to cylinders or other components of the haulingmachine suspension system 64. The information collected by theadditional sensors 62 may also be transmitted to the loading systemcontroller 78 and used along with the payload body visual data set todetermine the condition of the payload body 36 (i.e., empty, partiallyfull, or full).

Once the hauling machine 24 is ready to be loaded, a signal may be sentfrom the loading system controller 78 to the loading machine 26 to beginthe loading sequence. In a next block 114, the loading machine 26 scoopsor otherwise fills the payload bucket 50 with work material 37 locatedat the jobsite 20. In some embodiments, the loading machine 26 may alsohave one or more visual sensors 58 (i.e., camera, RADAR scanning device,LIDAR scanning device, 3D scanning device) attached to the payloadbucket 50 or other component of the loading machine 26. The one or morevisual sensors 58 may be configured to scan the payload bucket 50 andproduce a payload visual data set. The loading machine may also haveadditional sensors 66 mounted to the payload bucket 50, the attachmentarms 52, and/or other such location. The additional sensors 66 may beconfigured to collect the weight, density, or other such measurement ofthe work material 37 present in the payload bucket 50. The loadingmachine 26 may then transmit the payload bucket visual data set and theadditional sensor 66 data to the loading system controller 78.

In a next block 116, the loading system controller 78 may analyze thepayload body visual data, the additional sensor 62 data, the payloadbucket visual data set, and the additional sensor 66 data received fromthe hauling and loading machines 24, 26. In some embodiments, theloading system controller 78 may first create a payload map of thepayload body 36 based on the payload body visual data and additionalsensor 62 data. Moreover, the loading system controller 78 may then usethe payload map along with the data received from the hauling andloading machines 24, 26 to generate a set of loading sequenceinstructions for the hauling and loading machines 24, 26. In someembodiments, the set of loading sequence instructions may be optimizedto produce benefits and improvements such as but not limited to, theefficiency of loading the hauling machine 24 is improved, excess wear onthe hauling and loading machines 24, 26 is reduced, fuel consumption isreduced, and safety is improved. Additionally, optimizing the loadingsequence may help reduce the number of loading cycles (i.e., fillingpayload bucket 50 and dumping in payload body 36), minimize excessmovements of the hauling and loading machines 24, 26, reduce the overfilling or under filling the payload body 36 and other suchimprovements.

After the loading system controller 78 generates the set of loadingsequence instructions, then in a next block 118 the instructions may betransmitted to the hauling and loading machines 24, 26. In onenon-limiting example the payload optimization system 84 may be used tooptimize the hauling and loading machine 24, 26 which operate in asemi-automatic mode. In the semi-automatic mode, an operator is in theoperator compartment 32, 46 of the hauling and loading machine 24, 26and operates the hauling and loading machine 24, 26 during loading.Moreover, the set of loading sequence instructions may be transmittedfrom the loading system controller 78 to the hauling machine controlunit 34 and the loading machine control unit 48 and the commands and/orinstructions may be displayed on the hauling and loading machine displayunits 96, 98. More specifically, the operator of the loading machine 26may view the instructions sent by the loading system controller 78 andload the work material 37 in the designated location (i.e., the firsttarget dump location 80) of the payload body 36. Alternatively, thepayload optimization system 84 may be used to optimize the hauling andloading machine 24, 26 which operate in a fully autonomous mode. In thefully autonomous mode, the hauling and loading machine 24, 26 are notoperated by an operator manipulating the controls of each machine.Rather, the hauling and loading machine 24, 26 are automaticallycontrolled and guided by on-board machine intelligence and a variety ofsensors. As a result, the set of loading sequence instructions may besent from the loading system controller 78 to the hauling and loadingmachine control units 34, 48. Moreover, the loading machine control unit48 may receive the set of loading sequence instructions and the fullyautonomous control system will guide the loading machine 26 during theloading sequence.

Once the hauling and loading machine 24, 26 receive set of loadingsequence instructions, then in a next block 120 the loading machine 26may dump the work material 37 from the payload bucket 50 into thedesignated location (i.e., first target dump location 80) of the payloadbody 36. Moreover, the set of loading sequence instructions may specifythe first target dump location 80 for the loading machine 26 to dump thework material 37 based on the payload body visual data set, the payloadbucket visual data set and additional sensor data 62, 66 provided by thehauling and loading machine 24, 26. After the loading machine 26 dumpsthe work material 37 in the first target dump location 80, then in anext block 122 the one or more visual sensors 58 on the hauling machine24 may scan the payload body 36 and collect an updated payload bodyvisual data set. Moreover, the additional sensors 62 coupled to thehauling machine suspension system 64 may continue to collect additionaldata and information. The hauling machine 24 may then transmit thepayload body visual data set and the additional sensor 62 data to theloading system controller 78. Furthermore, the loading machine 26 mayhave scooped up an additional load of work material 37 and the one ormore visual sensors 58 on the loading machine 26 may scan the payloadbucket 50 and collect an updated payload bucket visual data set. Theadditional sensors 66 on the payload bucket 50 may continue to collectadditional data and information related to the weight of the workmaterial 37 picked up by the payload bucket 50. The loading machine 26may transmit the updated payload bucket visual data set and theadditional sensor 66 data to the loading system controller 78.

After the loading system controller 78 receives the data from thehauling and loading machines 24, 26 it may analyze the received data todetermine if the first load of work material 37 was optimally placed inthe first target dump zone 80. If, in a next block 124, the workmaterial 37 was determined to be optimally placed in the first targetdump zone 80 and the work material 37 in the payload body 36 is properlydistributed (i.e., fore-aft distribution and side to side distribution)then the loading system controller 78 may determine the state of thepayload body 36 (i.e., empty, partially full, completely full). If, in anext block 126, the loading system controller 78 determines the payloadbody 36 is partially full, then the loading system controller 78determine the payload body 36 may accept an additional load of workmaterial 37. As a result, the loading system controller 78 may designatea second or additional target dump zone 82 in the payload body 36 andthe method 106 may return to block 114. The payload optimization system84 may repeat the subsequent steps to continue loading the payload body36. Alternatively, if in block 128, the loading system controller 78determines the payload body 36 is full, then the loading sequence may beterminated and the hauling machine 24 may dump or otherwise deliver theload. Furthermore, when the payload body 36 is determined to be full,the loading system controller 78 may analyze the data received from thehauling and loading machines 24, 26 to determine whether the payloadbody 36 is overloaded or overfilled. In some embodiments, if the payloadbody 36 is determined to be overloaded or overfilled, the loading systemcontroller 78 may send a corrective action signal to remove,redistribute, or other such corrective action that may correct theoverloaded or overfilled condition of the payload body 36.

Alternatively, after the loading system controller receives the datafrom the hauling and loading machines 24, 26, it may determine that thefirst load of work material 37 was not optimally placed in the firsttarget dump zone 80. In a next block, 130 the payload system controller78 may signal that the load placement was not ok and continue to analyzethe state of the work material 37 in the payload body 36. If, in block132, the payload system controller 78 determines that a correctiveaction is possible to fix the payload placement, then the payload systemcontroller 78 may issue a corrective action such as but not limited to,dozing is needed, abnormal size boulder detected, or other suchcorrective action. Moreover, the payload system controller 78 may updateor correct the set of loading sequence instructions sent to the loadingmachine 26 in attempt to correct the payload condition. Once the issuehas been corrected, the loading system controller 78 may designate asecond or additional target dump zone 82 in the payload body 36 and themethod 106 may return to block 114. The payload optimization system 84may repeat the subsequent steps to continue loading the payload body 36.However, if in block 134, the payload system controller 78 determinesthat a corrective action is not possible to fix the payload placement,then the loading system controller 78 may issue a signal that thecurrent loading sequence should be aborted, the payload body 36 shouldbe dumped, and the sequence should start over.

While the foregoing detailed description has been given and providedwith respect to certain specific embodiments, it is to be understoodthat the scope of the disclosure should not be limited to suchembodiments, but that the same are provided simply for enablement andbest mode purposes. The breadth and spirit of the present disclosure isbroader than the embodiments specifically disclosed and encompassedwithin the claims appended hereto. Moreover, while some features aredescribed in conjunction with certain specific embodiments, thesefeatures are not limited to use with only the embodiment with which theyare described, but instead may be used together with or separate from,other features disclosed in conjunction with alternate embodiments.

What is claimed is:
 1. A payload optimization system for loading a setof work machines, the payload optimization system comprising: one ormore visual sensors operably coupled to a hauling machine, the one ormore visual sensors configured to scan a payload body of the haulingmachine and produce a payload body data set; a loading machine includinga payload bucket configured to load a payload into the payload body ofthe hauling machine; a loading system controller communicably coupled toeach of the hauling machine and the loading machine, the loading systemcontroller configured to: identify the hauling machine and the loadingmachine using a set of machine identifiers received from the haulingmachine and the loading machine; receive the payload body data set fromthe one or more visual sensors; generate a payload body map based on thepayload body data set; program a loading sequence of the payload bodybased on the payload body map and transmit the loading sequence to theloading machine; and display the loading sequence on a loading machinedisplay device, the loading sequence configured to guide a loading cyclebetween the hauling machine and the loading machine.
 2. The payloadoptimization system of claim 1, wherein the loading system controller isfurther configured to analyze the payload body data set to confirm thepayload body is empty and transmits a start signal to the loadingmachine to begin the loading sequence.
 3. The payload optimizationsystem of claim 1, wherein the loading sequence is programmed toidentify a first target dump zone for a first payload delivered to thepayload body and transmitting the first target dump zone to the loadingmachine.
 4. The payload optimization system of claim 3, wherein the oneor more visual sensors are configured to scan the payload body in acontinuous scanning mode to produce a continuous scanning data setincluding a placement of the first payload, wherein the loading sequenceincorporates the continuous scanning data set to identify one or moreadditional target dump zones for one or more additional loads deliveredto the payload body, wherein the one or more additional target dumpzones are communicated to the loading machine and continuously updatedbased on the continuous scanning data set.
 5. The payload optimizationsystem of claim 4, further comprising at least one pressure sensoroperably coupled to the hauling machine and configured to monitor andcollect a suspension pressure, wherein the loading sequence incorporatesthe continuous data set and the suspension pressure such that the one ormore additional target dump zones are continuously updated to produce abalanced payload within the payload body.
 6. The payload optimizationsystem of claim 4, further including one or more payload monitoringsensors operably coupled to the loading machine and configured tomonitor a load volume and load density of the payload in the payloadbucket, wherein the load volume and load density are transmitted to theloading system controller and the loading sequence incorporates the loadvolume and load density to identify the one or more additional targetdump zones.
 7. The payload optimization system of claim 1, wherein theloading system controller is configured to generate an event log basedon the loading sequence, the event log includes one or more eventsperformed by the hauling machine and the loading machine, wherein theevent log is analyzed to determine an amount of work performed by thehauling machine and the loading machine.
 8. A method of optimizing apayload position within a work machine, the method comprising:identifying a hauling machine and a loading machine using one or morevisual sensors coupled to a frame of the hauling machine; receiving apayload capacity of the hauling machine from a machine specificationdata base based on an identification of the hauling machine; receiving aloading capacity of the loading machine from the machine specificationdata base based on an identification of the loading machine; scanning apayload body of the hauling machine with the one or more visual sensorsto produce a payload body data set; generating a payload body map basedon the payload body data set; programming a loading sequence of thepayload body based on the payload body map and the loading capacity ofthe loading machine; and transmitting the loading sequence to theloading machine to guide a loading cycle of the hauling machine.
 9. Themethod of claim 8, wherein scanning the payload body further includesidentifying the payload body is empty and the hauling machine is readyto begin the loading cycle.
 10. The method of claim 8, whereinprogramming the loading sequence includes identifying a first targetdump zone for a first payload delivered to the payload body andtransmitting the first target dump zone to the loading machine.
 11. Themethod of claim 10, wherein operating the one or more visual sensors ina continuous scanning mode produces a continuous scanning data setincluding a placement of the first payload, and programming the loadingsequence incorporates the continuous scanning data set to identify oneor more additional target dump zones for one or more additional loadsdelivered to the payload body and transmitting the one or moreadditional target dump zones to the loading machine.
 12. The method ofclaim 11, further comprising at least one pressure sensor operablycoupled to the hauling machine and configured to monitor and collect asuspension pressure, wherein programming the loading sequenceincorporates analyzing the continuous scanning data set and thesuspension pressure such that the one or more additional target dumpzones are continuously updated to produce a balanced payload within thepayload body.
 13. The method of claim 11, further comprising one or morepayload monitoring sensors operably coupled to the loading machine andconfigured to monitor a load volume and load density, whereinprogramming the loading sequence incorporates the load volume and loaddensity to identify the one or more additional target dump zones. 14.The method of claim 8, wherein programming the loading sequence includesgenerating an event log capturing one or more events performed by thehauling machine and the loading machine, and the event log is analyzedto determine an amount of work performed by the hauling machine and theloading machine.
 15. A controller for optimizing an operation of a workmachine, the controller comprising: a machine specification moduleincluding a payload capacity for a hauling machine and a loadingcapacity for a loading machine; a vision data module configured toreceive a visual data set collected from one or more visual sensorsoperably coupled to the hauling machine, the one or more visual sensorsconfigured to scan a payload body of the hauling machine and produce apayload body data set; a payload mapping module configured to receivethe payload body data set and generate a payload body map; a loadingsequence module configured to program a loading sequence of the payloadbody of the hauling machine based on the payload body map and theloading capacity; and a communication module configured to transmit theloading sequence to the loading machine to guide a loading cycle of thehauling machine.
 16. The controller of claim 15, wherein the loadingsequence is programmed to identify a first target dump zone for a firstpayload delivered to the payload body and the first target dump zone istransmitted to the loading machine.
 17. The controller of claim 16,wherein the vision data module is configured to receive a continuousscanning data set including a placement of the first payload collectedby the one or more visual sensors, and the loading sequence isprogrammed to incorporate the continuous scanning data set to identifyone or more additional target dump zones for one or more additionalloads delivered to the payload body and the one or more additionaltarget dump zones are transmitted to the loading machine andcontinuously updates based on the continuous data set.
 18. Thecontroller of claim 17, further comprising a pressure sensor monitoringmodule configured to receive a suspension pressure monitored andcollected by one or more pressure sensors coupled to the haulingmachine, wherein the loading sequence is programmed to incorporate thecontinuous scanning data set and the suspension pressure such that theone or more additional target dump zones are continuously updated toproduce a balanced payload within the payload body.
 19. The controllerof claim 18, further including a payload monitoring module configured toreceive a load volume and a load density of a payload in a payloadbucket of the loading machine, wherein the loading sequence isprogrammed to include the load volume and the load density to identifythe one or more additional target dump zones.
 20. The controller ofclaim 15, wherein the loading sequence module generates an event logbased on the loading sequence, the event log includes one or more eventsperformed by the hauling machine and the loading machine, wherein theevent log is analyzed to determine an amount of work performed by thehauling machine and the loading machine.